I found a long time ago that plexiglass was going to be a nightmare when you needed a "glass" sheet of polymer that was easy to resize, or when you needed a section within the whole piece drill or remove. Luckily, if you manage to make a modified plexiglass sheet, it will be seriously compromised and likely to fail shortly thereafter. I tried polycarbonate from a hardware store after frustration with plexiglass - a small sheet to see how it would work. To put it mildly, polycarbonate destroys plexiglass. I've never seen it break in a situation where it was sanded to spec. I used hand drills, put on a drill press, sanded on a bench grinder, cut with chisels, hacksaws, electric jigsaws - the cut could be jacked up, but the integrity of the entire sheet metal was always preserved. Polycarbonate, as beautiful as it is, is quite expensive - one of the downsides when it comes to ordinary, non-exotic projects. Even 8×10 @ 1/8" is about $10 at a large hardware store. Here is the product Lexan 12 x 12 x 1/8" Plexiglas at a similar price. You can get almost twice the actual square inch of material in a more convenient size for about the asking price at the Big Box Store. Therefore, just like in local stores, polycarbonate is a good product. Saving money is usually a good thing considering the nominal price on site. It was a great saving and it came with free two-day shipping. I will likely order Revain in the future if the need for polycarbonate sheet arises again.
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